Catalysts



Patented Dec. 5, 1944 CATALYSTS V Preston L. Velt man, Flshkill, N.'Y., asslg'nor- The Texas Compa poration of- Delaware originagsgpplication February 18,

No Drawing.

1941, Serial No. 379.

plication May 2, 1942.

Canada and Great Bri 7 Claims.

. This invention relates to the catalytic treatment of hydrocarbons, particularly petroleum hydrocarbons; The invention is primarily con- 'cerned with catalysts adapted for use in the conversion of hydrocarbons to hydrocarbons of increased value for motor fuel. The invention.

' especially relates to catalysts for use inthe treatment of hydrocarbons to effect conversion of high New York, N. -Y., a cog Divided andihis ap- Serial No. 441,564. In

tain January 23, 1941 the-abilvity to catalyze the reaction in question are intended.

It has been found that the properties'o'f .a wide I variety of materials which have been proposed for use as cracking catalysts can be improved in one or more directions by combining the materials with a hydrated aluminum fluoride. It

molecular weight hydrocarbons into low molecuular weight hydrocarbons for the production of hydrocarbons suitable for the manufacture of internal combustion motor fuel. -In addition, it

r'elates'to catalysts for the reforming of hydrocarbons such as the reforming of virgin and cracked naphtha hydrocarbons to improve their value as constituents of motor fuel.

The present, applicationapplication Serial No. I 18, 1941. Application Serial No. 379,483 is a continuation-in-part of my application Serial No.

311,943, filed December 30, 1939.

has-also been found that the catalysts should be substantially free ofsodium and potassium,

these elements apparently acting to destroy the catalytic activity of the 0 her ingredients, particularly at high"temp'era ,ures.= The catalysts of the invention, therefore, are substantially free of sodium and potassium andcomprise a catalytically active. material, which is preferably v porous in structure, in combination or admixture with a hydrated aluminum fluoride. .In general is' a division of my 379,483, filed February In the catalytic cracking of oils to produce gasoline it hasbeen the common practice to employ kieselguhr, activated clays, artificial zeolites, and synthetic compositions composed essentially of alumina and silica. a

Ordinarily theoil to be cracked is heated and as catalysts suchmaterials as fullers earth,

vaporized and the hot vapors are brought into contact with the solid catalyst under/controlledconditions of temperature and pressure. The reaction products, including gas, gasoline hydrocarbons and higher boiling hydrocarbons, are separated in conventional ways. During the conversion coke-like material is deposited on the catathe catalysts contain a major proportion of the catalytically active material-and a minor proportion of the hydrated aluminum fluoride. It

has been found in many cases that a relatively small amount of the hydrated aluminum fluoride, 'for example, 1 per cent by weight or even less, is effective to improve the properties of the catalytic material.

While it' is not intended that the invention should be limited to anytheory of operation, 'it' appears that the hydrated aluminum fluoride functions as an activator or promoter-in the combined catalysts. The results obtained can not be explained on the basis of the mere additive efiects of the ingredients since by replacing 1 a small portion of a catalytically active material with a hydrated aluminum fluoride marked imlyst, reducing its activity and ability tocatalyze .the hydrocarbon conversion, and. it becomes necessary 'to reactivate the catalyst. This is accomplished by burning oil the coke'with a stream of airor oxygen-containing gas. After .thus reactivating the catalyst, it may be reused in cracklng additional quantities ofv oil.

The present invention is based upori'the discovery thatcompositions comprising a hydrated alu'min-um fluoride in combination with a catafluoride that is present in the'co'mpleted cata-- lytically active material, especially a catalyti' cally active material that is porous in structure, constitute catalysts which are particularly valuable foruse inthe conversion of relatively high molecular weight hydrocarbons to low molecular weight hydrocarbons and for use in the reformingof virgin and cracked hydrocarbon distillates. In referring to a catalytically active material, it

will be understood that materials which possess provement in the catalytic action of the material has been obtaine The catalysts are designed for use at elevated temperatures-catalytic cracking and reforming are preferably carried out at temperatures above 700 F.- -and are substantially stable and nonvolatile at temperatures at least up to about 1200 F. The particular hydrate of aluminum lyst will depend in many cases upon the temperature to which the catalyst is heated before and during use, andthe duration of the heating. Aluminum fluoride in 'the form of thehemi-hydrate, AlFa. I to 1200 F. It is known to exist as the monohydrate, A1F3.1H2O, at temperatures up to about 500 'F.,'and may exist, at least partly,-in this higher hydrate form at higher temperatures, particularly when associated with a catalytically active material as in the catalysts of the inven- /zHZO, is stable at temperatures up tion. Accordingly, when the catalysts are made up by-combining a hydrated aluminum fluoride, as such, with a catalytically active material, it is preferred to employ the hemi-hydrate, and it is believed that when forming the fluoride in situ, as is done in. many cases, 'or when using a: higher hydrate, in the final catalyst the aluminum fluoride may be in the form of the hemihydrate to a large extent;

A preferred form of catalyst, which has been found to be particularly effective as a cracking catalyst, comprises solid hydrated aluminum fluoride associated with a catalytically active solid adsorbent material, either natural or artificial. Such adsorbent materials include. siliceous materials, such as fullers earth, activated clays,

aluminum silicates, etc., as well as non-siliceous materials, such. as alumina and magnesia.

Other adsorbent materials may be used upon .which the fluoride may-be adsorbed or dispersed.v

While adsorbent materials have been mentioned specifically, it is, nevertheless, contemplated that the material with which the aluminum fluoride is associated may comprise other finely divided orpulverulent solid materials.

Theinvention thus contemplates a composite or mixed catalyst consisting of hydrated aluminum fluoride, and particularly the hemi-hydrate, in combination with a secondary material or support which is catalytically active. Stated. in another way, it may be defined as a composite catalyst consisting of solid catalytically active adsorbent material-having the fluoride associated with the adsorbent material in a stable substantially non-volatile form. The catalyst is thought to be particularly efiective when in a porous non-fused form. x l

The catalysts of the invention are especially valuable for use the vapor phase cracking of hydrocarbons, especially petroleum hydrocarbons. In this operation the hydrocarbon vapors are passed in momentary contact with a solid catalyst which may be in the form of pieces or lumps but. is preferablyin the form of pellets. The temperature may be maintained from 700 F. upwards, for example, the temperature may vary from 700 F. to 1100 F. although it is generally regarded as preferable to operate at temperatures within the range of 800 to 1000 F. Various pressures may be maintained during this operation; for example, pressures [from atmos pheric to about 100 to 300 pounds per square inch or higher.

The. specific-manner in which the catalysts are prepared will depend'to a considerable ex-' from six to eight hours. The calcining is effective a to remove the binding agent'and also appears to produce another important result. It has been found to be important in preparing the catalysts to have present in the mixture or dispersion a substantial proportion of free and/or combined A large part of this water is removed water. during calcining and it isbelieved this removal ofwater causes a desirable change in the physical nature of the catalyst. v

The followingJare examples of speciflcfcata- 10 minum fluoride hydrate being added to the mix-v ture prior to precipitation of the magnesium fluoride.

2. Aluminum fluoride-magnesia catalyst, containing about AlFa hemi-hydrate, prepared by forming a slurry of commercial magnesia and treating the slurry with solutions of aluminum chloride and ammonium fluoride.

3. Super Filtrol+aluminum fluoride hemi-hydrate comprising a physical mixture containing about 10% by weight of the fluoride ground to around to mesh.

In each case the catalysts after drying, pelleting and calcining by heating at a temperature of around 1000" F. for from 6 to 8 hours were tested as cracking catalysts in the cracking 'of' virgin gas oil to produce gasoline. The tests demonstrated that these particular catalysts,

were effective in producing a high yield of asoline with low yields of gas and carbon.

Catalyst 1, for example, was compared with a standard catalyst, 'which will be subsequently referred to as catalyst A, and which is a silicaalumina type of catalyst containing a high ratio of silica to alumina. According to this comparison, at a cracking temperature of about 1000 F.,

the fluoride catalyst gave a substantially higher yield of gasoline than the standard'catalyst. In

addition, the yields of gasand carbon were sub stantially lower than were those obtained with 0" the standard catalyst.

The preparation of two catalysts, namely, catalyst B, consisting of a compound containing about 80% $102. 15% MgFz, and 5% A1F3. H2O, and catalyst C comprising the above-men- 45 tioned standard catalyst A containing about 10% aluminum fluoride hemi-hydrate will now be described more specifically.

pared by neutralizing a dilute solution of sodium silicate with dilute hydrochloric acid, iiltering and washing free of sodium in the wet state. tent upon the catalytically active material used Ana /21120, was added to the slurry while stir-- ring, the stirring being continued for about 20 minutes; i

This slurry was then treated with about 2 liters of an aqueous solution of magnesium chloride containing about 7% by weight of, MgClz, and stirring continued for about one-hour.

ThepI-I was then adjusted to about seven with dilute hydrochloric and ammonium hydratesolutions. The resulting precipitate was removed by filtration and-' washed once by slurrying with water and filtering. The washed precipitate was dried to about 20% water content at 250. .F. and pelleted. The pellets were calcined at about 1000 F. for six hours.

nesia.

- Catalyst m A batch of the previously mentionedstandard catalyst "A,- in the. form of pills, was moistened with aluminum chloride solution. The

moistened pills were heated at about 200 F.

for about three hours so as to remove approxi-' mately one-half of the water added with the and it may be that the magnesia remains. as such in the final catalyst.

' .On mixing a slurry prepared by any of the aluminum chloride solution. Thereafter the pills were cooled to room temperature. The

cooled pills were then moistened with an aqueous solution of ammonia'fluoride. These pills were then maintained at a temperature of around 212 F. until dry. Following this they were cal cined by heating at 1000 1. for four hours.

The aluminum chloride and ammonium fluoride solutions used were of sufiicient concentration to produce a final product containing 10% by weight of aluminum fluoride.

above procedures with the silica gel a combination slurry is obtained which is preferably dried to reduce the water content to the desired amount, preferably of the order of per cent,

mixed with an organic binding agent and calcined. Acatalyst of this class may also be prepared by mixing a hydrated'aluminum' fluorideand .magnesium fluoride .with a hydrated silicaalumina gel. The resulting slurry, after re- Many of the more important catalysts for use in accordance with the invention. contain silica and alumina. Catalysts of this type are preferably prepared by'using as a base a hydrated silica gel free from sodium and potassium, and

preferably other alkali metals, and incorporating in the gel the hydrated aluminum fluoride and other materials to be used. The .resulting mixture or dispersion is then heated to remove water to produce'a relatively dry product which.

however, will contain a substantial proportion of free or combined water. The product is then preferably mixed with a small proportion of a binding agent and is calcined to remove this agent and a part of the water. In making up a catalyst of this class it is preferred to make up the aluminum fluoride by reaction between anot er aluminum salt, such as aluminum chlori e, and a fluoride of aweak base, such as amonium fluoride, or hydrofluoric acid. These catalysts preferably contain a major proportion of silica and may contain other materials in addition to the three named. For example, val- 3 uable catalysts of this class contain a proportion of zirconia. X

As a feature of the invention it has been found that especially valuable catalysts may be prepared to contain silica. alumina, a hydrated aluminum fluoride, and magnesia or magnesium fluoride. These catalysts may be prepared, for example, by mixing an aluminum oxide -magnesium oxide gel with hydrofluoric acid or with a salt of a weak base with hydrofluoric acid, such as ammonium fluoride, in the presence of water to produce a slurry containing aluminum fiuoride,alumina, magnesium fluoride and magnesia, and then mixing'this slurry with a rela- 17 tively large proportion of a hydrated silica gel free of sodium and potassium. Similar. catalysts may be prepared by mixing an aluminum oxide gel with hydrofluoric acid or ammonium fluorideand with magnesia to produce a combination slurry suitable for addition to' the hydrated silica gel.

A slurry for mixture with silica gel and having properties for catalyst preparations similar to the properties of the slurries describ d above fluoride: or hydrofluoric acid with a soluble. aluminum salt,- such as' aluminum chloride, in the. presence may be prepared by reacting ammoniu til suitable catalysts are given:

was Justacid to litmus.

the gel was washed v with one-half hour of stirring. 'Thisthorough ducing the water. content, may e' treated as above described to produce a hed catalyst. .The catalysts. comprising silica, alumina, a magnesium compound, and aluminum fluoride consisting of 100 parts by weight preferably con- 'tain these materials according to analysis in the followingproportions: 50 to 95 parts byweight silica, 1 to 20 parts by weight a1umina, '1'to 20 parts by weight magnesia, and 1 to 20.parts by weight aluminum fluoride, considered as the am hydrous salt. Catalysts which are especially preferred are those which contain in 100 parts by weight to 93 parts of silica, 1 to- 10 parts of alumina, 3 to 7 parts of aluminum fluoride,

and 1 to 4 parts of magnesia. As previously indicated', the aluminum fluoride is present in the hydrated form, probably the hemi-hydrate. and

the magnesium, which is considered as being present as the oxide, may-or may not be pres-- ent in part at least in the form of the fluoride.

In order that the invention. may be understood more fullythe following additional examples which illustrate processes Example I A substantially sodium-free hydrated silica .gel was'prepared from an aqueous solution containing 1650 grams of sodium silicate by treatment with hydrochloric acid and finally adding ammonium hydroxide until the resulting slurry I The gel was thenflltered, washed with three liters .of water. and then with three liters of cubic centimeters of concentrated. hydrochloric .acid. a g i To complete the washing the gel was slurried with an aqueous solution containing 100 grams of AlClaiGHzO in three liters of water, and finally with three liters of .water washing was effective substantially to remove sodium from the gel. 395 cubic centimeters of dilute ammonium hydroxide were'added to a solution containing I99 grams AlCl3.6I-I2O in two liters of water, this making the system just 'basic to litmus and causing the precipitation of a gel. The gel was removedby filtration and washed thoroughly with water. This hydrated-alumina was slurried with two liters of water and an aqueous solution containing 40.4 grams of ammonium fluoride was added. 10.4 grams of magnesia were then disperse in the system. The systemwas then combined with. the silica gel, which contained about percent 'water and theresulting mixture was stirred until a smooth slurry was obtained. After standing the product was filtered and thefilter cake-was dried at 250 F.

to reduce the water content. The dried material was ground to 40 mesh, mixed with 4 per cent flour and 2' per cent stearic acid and formed into cylindrical pellets for preparing water containing five inch in diameter and. i;

' grams of A1Cl3.6H2O in six liters of water.

4- inch in height. The pellets were calcined for six hours at 1000 F. A portion ot-the resulting catalyst was-ignited from 1000 F. to 1800 F. to

provide an indication of the water content. Another portion of the catalyst was analyzed. This analysis showed the following: 92.8. per cent SiOz, 0.7 per cent A1203, 3.5 per cent AlFs, and 3.4 per cent MgO. The loss of weight on ignition, to 1800 F. was 2.4 per cent. It will be 11nde1-.

stood that in grouping the elements in the above manner it is not intended to indicate that the elements are necessarily combined as indicated. For example, it may be that, a portion of the fluorineis combined with magnesium in the form of magnesium fluoride. Also the aluminum fiuo-' ride is undoubtedly in the hydrated form.

Example II AJC13.6H2O in five liters of water. After stirring.

dilute ammonium hydroxide was added to make the solution neutral to litmus and 10.4 grams of MgO were mixed in. A combined slurry was prepared by mixing this slurry with an amount of sodium-free silica ge1.(containing about 90 per cent water) corresponding to about 425 grams of dry silica. The combined slurry was permitted to stand, a layer of supernatant liquid was drawn off, and the remaining product was flltered and dried to reduce'the water content to 20 per cent, which is regarded as being an especially desirable procedure. The catalyst was finished in the manner described in Example I. The analysis showed 89 per cent $102, 2 per cent A1203, 3 per cent AlF3 and 1 per cent MgO, and the loss on ignition from 1000 to 1800 F. was 3 per cent.

Example III An aqueous solution containing about 340 grams of ammonium fluoride in one liter of water was added to an aqueous solution containing about 556 grams of A1C13.6H2O and about 163 grams of MgClfiH-zO in one liter of water. -The resulting solution was evaporated to dryness and then-heated at 1000 F. to drive ofi ammonium chloride and form about 250 grams of a mixture of aluminum fluoride and magnesium fluoride.

5,447 grams of hydrated silica gel prepared in a manner similar to that described in'Example I and containing 430 grams of SiO2 on a dry basis was mixed with a solution containing about 22 150 cc. of dilute. ammonium hydroxide was added to the resulting solution, this making the solution basic to litmus. The resulting silica-alumina gel was filtered from the remainder of'the solution and washed thoroughly with water.

About 44 grams of the mixture of aluminum fluoride and magnesium fluoride prepared asdescribed above were slurried in six liters of water and the slurry was mixed with the combination silica-alumina gel. After stirring thoroughly, the system was filtered and the filter cake was dried forabout twenty hours at 250 F. to reduce the moisture content to about 24 per cent. The dry composition obtained was ground to mesh. and further treated as described in Example I.

* .catalyst'contained 53.3 per cent SiOz, 18.5 per r as Example IV 29 grams of MgCOs and cc. of dilute hydro chloric acid were added to a solution containin 195 grams of A1C13.6H2O in flve liters of water. Dilute ammoniumhydroxide was then added until the solution was just basic to litmus, thereby forming alumina-and magnesia. After stirring, a solution containing about 50 grams of 48 per cent hydrofluoric acid in 500 cc. of water was added to the system. The resulting mixture, whichcontained a precipitate comprising aluminum fluoride and magnesium fluoride, after stirring was neutral to litmus. The precipitate was 1 1 filtered from the solution and washed thoroughly with water. The washed precipitate was slur- .ried in six liters of water and a quantity of hydrated silica gel prepared in a manner similar to that described in Example I sufficient to contain 438 grams- 01 dry SiOa was mixed with the slurry. After stirring, the system was filtered and the combination gel obtained was dried at 250 F. to a 21 per cent moisture content. The relatively dry gel was ground to 40 mesh an finished as described in Example I.

. Example V A hydrated aluminum fluoride was prepared by evaporating a solution containing 287 grams of aluminum chloride and 132 grams of ammonium fluoride in two liters of water, until the water content was reduced to that corresponding to the .hemi-hydrate., 57 grams of this hydrated aluminum fluoride were mixed intimately with 240 grams of an acid treated bentonite clay marketed under the trade name-Super Filtrol. The resulting mixture was mixed with 4 per cent flour and 2 per cent stearic acid, pelleted and calcined at 950 F. for five hours. Analysis indicated that the cent A120: and 19.2 per cent AlFa. The loss on ignition from 1000 to 1800 F. was 14 per cent indicating that the catalyst contained a substantial proportion of water, and that some decomposition occurred at this elevated temperature.

Example VI A catalyst was prepared in the same manner as described in Example V, but using 20 grams of the hydrated aluminum fluoride and about 180 grams of Super Filtrol. Analysis indicated that the final catalyst contained 8.9 per cent AlFs.

\ Example VII An amount of sodium-free silica gel prepared in a manner similar to that described in Example I corresponding to 400 grams of dry silica was mixedwith 100 grams of hydrated aluminum fluoride (AlFaxHzO) and ground until the materials were intimately mixed. The catalyst was-dried at 250 F. to 11.1 per cent moisture content and finished'as described in Example I. Analysis of the catalyst indicated the following: per cent SiO2, 4.9 per cent A1203 and 10.4 per cent AlFa. The loss on ignition from 1000 to 1800 F. was 7.9 per cent.

Example VIII utes, 500 cc. of dilute ammonium hydroxide were added to make the slurry just basic to litmus. The

ass-aria the filter cakewas washed with water. The resulting system was snowe -to sand. filtered, and

aluminum fluoride-alumina gel was s'lurrie'd in three liters of water and this'slurry was mixed with a slurry containing in three liters of water a silica gel prepared in a manner similar to that described in Example I from 1230 grams of sotain 58.3 per cent $102, 24.6 per cent A1203, and

12.9 per centAlFa.

Example I)! The catalyst or this example contained a prodnet-resulting from the reaction of hydrated aluminum fluoride with vated temperature.

aluminum powder at an ele- This product was prepared by mixing 186 arts by weight of the aluminum fluoride with 27 parts by weight of aluminum powder and heating the resulting mixture to 100 F. in the presence of air. A vigorous reaction resulted. The resulting'product was then heated at 350 100 mesh.

A slurry was made up by adding .a hydrated silica gel prepared from 1400 grams of sodium silicate in a manner similar to that described in Example I to a solution of 236 grams of monsmo a smooth slurry resulted and then afterstanding 540 cc. of dilute ammonium hydroxide were added to make the slurry just basic to litmus. The precipitate was filtered from the solution and washed .with water. To this slurry 50 grams of the aluminum fluoride-alumina reaction product were added and the resulting mixture was stirred for one hour and filtered. The product obtained as a I result of this procedure was'dried at 250? F. to a 4., per cent moisture content and finished as described in Example I. Analysis showed the catalyst to contain 69.7 per cent SiOz, 14.6 per cent 1 A1203, 9.7 per cent ZrOz, and 4.9 per cent AlFa.

Example X 'A silica gel was prepared from 1640 grams of sodium silicate in a; manner similar to that described in Example I except thatfinal washing with water was omitted. The silica gel was added to a solution containing 180 grams of AlClafiHzO and 8'7 grams of Zr(NO3) 4.5H2O in five liters of water. After permitting the system to stand 550 'cc'. of dilute ammonium hydroxide were added until the solution was just basic to litmus The precipitate was filtered from the solution and washed by slurrying in three liters of water containing three cc. of concentrated ammonium hydroxide. The washed filter cake was slurried in a solution containing 31- grams of NHgHEa in four liters of water. After stirring the mixture and allowing 'it to stand, sumcient' dilute ammonium hydroxide was added to make the solution just basic tolltmus. The mixture was-stirred for one hour and filtered and the filter cake was, dried at 250 F. .to an 11 per cent moisturecontent and finished asdescribedin'ExampleL v 3 -The catalysts described in the foregoing ex- 1 amples are particularly adapted for use in the I vapor phase catalyticcracking of petroleum hy- F. for two hours and ground to so that the .octane value ature of about 900" F. and under atmospheric pressure. The liquid product obtained during the intervals of time indicated wasseparately ac- 15 cumulated and analyzed to determine the content ofdebutanized gasoline having an end bolling point of 400 F. Also the were collected and analyzed to determine'their constitution. Example XI for-the crackingof gas. oil in the'manner out.- lined above. After a two-hour period, it was found that the yield of gasoline (volume per cent, basis charge) was 33.4 'per cent and that the octane yalue of the gasoline.(CFRM method) was 79.9. Also, the carbon" deposited was determined and it was iound that ions of gasoline obtained and the pounds 01' carbon was 5.3. The gas production was 5.1 per cent by weight of the charge and analysis of the gas showed that it contained 14.4 per cent by volume hydrogen. In a run carried out under but usinga standard catalyst containing silica,

alumina, and zirconia, which is regarded as being an especially valuablecatalyst, the'yield and' octane value of the gasoline were substantially the same as obtained with the above catalyst but the gasoline-carbon ratio was only 3.1..- Also, 10.1 per cent by weight gas wasproduced and this gas contained 21.8 per cent by volume hydrogen.

Example X II v The catalyst described in Example V was used for the cracking of gas oil in the manner outlined Afterajour hour period, it was found above. that the yieldfof gasoline was 30.8 per cent and of the gasoline. (CFRM method) was 80.3. s A catalyst, similar to thatof ExampleV except that aluminum fluoride was not added,

' which catalyst was prepared. by pelleting a mixture of 94 per cent by weight Super Filtrol and 6 percent aluminum stearate, and calcining for eight hours at 1050 F., gave a yield of gasoline of 19.3 per centunder substantially the same conditions. aluminum fluoride materially increased the yield of gasoline.

amples of the use of thecatalysts of the invencatalysts of the class defined above, particularly those specifically'disclosed, may be used in place ofthe catalysts employed in theseexam'ples. to produce equivalent results. The advantages flowing from the use of a hydrated aluminum fluoride with a catalytically active material will gaseous products the ratio between the gal-' the same conditions tionv are merely representative and that other tower was maintained at a temper. j

catalyst describe in Example Iwas used I Thus. the addition'of the hydrated I:

- It will be understood that the above'two ex- ,1

. 'vary depending upon the characteristics 'of the material. In general, where the catalytically active material is deflcientin producing high yields, the addition of the fluorideproduces a catalyst 7 capableor giving higher yields. In other cases,

the hydrated aluminum fluoride 'acts to improve the type'of gas produced in-the catalytic reaction, to reduce the amount of gas produced, or to reduce the amount or carbon deposited in relation-t'o the amount of gasoline produced.

Whilevapor phase cracking has been described above, it is contemplated that the catalysts of this invention may be employed in liquid phase cracking. The characteristic of low carbon deposition'with these catalysts, even at low temperatures; i. e., 700 to 750 F., and therefore in the presence of liquid hydrocarbons, indicates their suitability, for cracking under substantial pressures. s

.It' is contemplated that the powdered form of proportion of the catalyst and the aluminum flu-' oride being in hydrated =form and being dispersed throughout the catalyst, said catalyst being obtainable by a process comprising mixing an aqueous composition containing aluminum fluoride, alumina, and at least one compound selected from the group consisting of magnesia and magnesium fluoride with-ahydrated silica gel, and drying the resulting mixture.

' 3. A solid catalyst of hydrocarbons at -elevated temperatures which is substantially free of sodium and potassium and the catalyst is particularly applicable to a crack-. ing system wherein the catalyst is passed continuously through the reaction zone.

When the catalysts are usedas solid particles or pellets and the hydrocarbons to be treated are passed through a body of solid catalyst, various space velocities may be selected. In general, dependent upon the temperature and pressure maintained and other conditions of operation, the space velocity will vary .from. about 1 to 10.

As appears from the examples, the proportion of hydrated aluminum fluoride in the catalysts maybe varied. The catalysts preferably contain from 1 to per centaluminum fluoride, considered as the anhydrous salt.

It is an object of the invention to use a solid type of catalyst containing the fluoride in an ac tive form and in a form which. is stable and substantially non-volatile at temperatures up to about 1200 F. It may be employed in 'pellet, pill or powdered form.

It will thus be seen that the invention provides an improved process for the catalytic cracking of relatively high molecular weight hydrocarbons, particularly petroleum oils which boil above the gasoline range, involving the use of improved catalysts. The invention also provides novel cat- 'alysts which are of particular value for use in catalytic cracking but may also be used, for example, in the re-forming of virgin and cracked hydrocarbon distillates.

Since changes may be made in the products and processes described above without departing from the scope of the invention, it is intended that the description shallbe taken as illustrative and not in a limiting sense. 1

1. A solid catalyst adapted for the conversion of hydrocarbons at elevated temperatures which is substantlally'free of sodium and potassium and comprises in combination silica, alumina, aluminum fluoride and a magnesium compound selected from the group consisting of magnesia by weight silica,

comprises. in combination silica, alumina, aluminum fluoride, and at least one compound selected from the group consisting of magnesia and magnesium fluoride, one hundred by, weight of said catalyst containing by analysis 50 to'95 parts 1 to 20 parts by weight alumina,

. 11 to 20 parts by weight aluminum fluoride, and

1 to 20 parts by weightmagnesia, the aluminum fluoride being in' hydrated form and; being dis f persed throughout the catalyst,

4. A solid catalyst adapted for the conversion ofhydrocarbons at elevated temperatures which is substantially free of sodiumand potassium and comprises in combination silica, alumina,

aluminum fluoride, and at least one compound selected from the group consisting of magnesia and magnesium fluoride, one hundred parts, by weight of said catalyst containing by analysis 80 to 93 parts by weight silica, l to 10 parts.by weight alumina, 3 to 7 parts by weight aluminum fluoride and 1 to 4 parts by weight magnesia, the aluminum fluoride being .in hydrated form and being dispersed throughout the catalyst.

5. A solid catalyst. adaptedfor the conversion of hydrocarbons at elevated temperatures which is substantially free of sodium and'potassium' and comprises a major proportion of silica incombination with alumina, zirconia, and a hydrated aluminum fluoride, said catalyst being prepared by a process comprising preparing a hydrated, plastic, substantially homogeneous mixture com prising a hydrated aluminumfluoride, alumina, zirconia, and silica; and drying the mixture.

6; The process for preparing catalystsadapted for the conversion of hydrocarbons at elevated temperatures which comprises mixing a hydrated silica gel free of sodium and potassium with an;

and magnesium fluoride, the silica comprising a major proportion of the catalyst and the aluminum fluoride being in hydrated form and being dispersed throughout the catalyst.

ZilA solid catalyst adapted for the conversion of hydrocarbons at elevated temperatures which is substantially free of sodium and potassium and comprises in combinationsilica, alumina, aluminum fluoride and a magnesium compound selected from the group consisting of magnesia and magnesium fluoride, the silica comprising a major aqueous slurry comprising alumina, a hydrated aluminum fluoride, and a'compound selected from I partially drying the resulting mixture, pelleting the partially dried product, and calcining the pellets, said hydrated silica gel' and said aqueous slurry being employed in proportions such that 100 parts by weight of the resulting catalyst con- 4 tains to 93 parts by weight of silica.

PRESTON L. VELTMAN.

adapted for the conversion 

